Liquid disposable plastic container

ABSTRACT

A plastic vial having a fill port with a structure that is easily collapsible, is sealable in less time, and that minimizes the residual stresses in the vial after it has been filled and sealed. The structure of the fill port includes a proximal end, with respect to the body of the vial, and a distal end, also with respect to the body of the vial. The proximal end is selected from the group consisting of a diamond-shaped end, an elliptical end and a circular end. Additionally, the vial has dispensing openings that minimize the effects of distorting a dispensing end of the vial when the vial is opened.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of U.S. ProvisionalPatent Application No. 60/427,721, entitled “LIQUID DISPOSABLE PLASTICCONTAINER,” filed Nov. 20, 2002, the entire disclosure of which isincorporated herein by reference.

TECHNICAL FIELD

[0002] The invention relates to containers in general, and morespecifically, to plastic containers that can be filled with liquidmedication.

BACKGROUND

[0003] There are two forms of drug delivery devices for inhalationmedication, metered dose inhalers (MDI's) and nebulizers. Nebulizationis the most effective delivery technique for respiratory medication. Anebulizer is a small, hand-held unit that connects to a forced airsource and turns the medication into a fine mist that is inhaled. Themedication to be nebulized is provided in a unit dose vial designed fora single use, or unit of use. For administration, the patient dispensesa unit dose into the nebulizer cup, or bowl. Often patients require amedication that is not commercially available and these medications areprepared by compounding pharmacies. After the pharmacist prepares themedication, individual doses are placed into single, unit dose plasticvials, which are then crimped and sealed by a thermal impulse heatsealer. Relatively long sealing times, however, are necessary withconventional vials to achieve a satisfactory crimp and seal of the openend of the vial. In addition, the crimping and sealing processes causeresidual stresses in the structure of the vials. The stresses may resultin a weakness in or around the seal or the seams of the vial, which mayultimately cause the vial to leak. A vial that minimizes residualstresses while at the same time substantially reducing the sealing cycletime is needed.

[0004] Plastic vials that feature break-away caps, or tips, which areintegrated into the vial, are known to those of ordinary skill in theart. To administer a nebulization treatment, the patient, or care-giver,twists the break-away tip and squeezes the medication into the nebulizerbowl. However, often the process of removing the break-away tip distortsthe dispensing opening resulting in a smaller dispensing opening thanwas designed for the vial, and sometimes, a completely blocked opening.Therefore, a vial that has a dispensing opening that minimizes theeffects of removing the break away tip is needed.

SUMMARY

[0005] The present disclosure provides a plastic vial having a fill portwith a structure that is easily collapsible and that minimizes theresidual stresses in the vial after it has been filled with medicine andsealed. According to one embodiment, the structure of the fill portincludes a circular end that is proximal to the body of the vial, and anelliptical end that is distal to the body of the vial. According toanother embodiment, the structure of the fill port includes a proximalend, with respect to the body of the vial, and a distal end, also withrespect to the body of the vial. The proximal end is selected from thegroup consisting of a diamond-shaped end, an elliptical end and acircular end. The distal end is selected from the group consisting adiamond-shaped end and an elliptical end. A vial according to thepresent embodiments can be sealed in less time as compared to the timeto seal conventional vials. Additionally, other embodiments havedispensing openings that minimize the effects of distorting thedispensing end when the break-away tips are removed.

[0006] These and other features, and advantages, will be more clearlyunderstood from the following detailed description taken in conjunctionwith the accompanying drawings. It is important to note the drawings arenot intended to represent the only form of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1 is a top view incorporating one embodiment of the presentdisclosure.

[0008]FIG. 2 is an end view of the embodiment of FIG. 1.

[0009]FIG. 3 is a detail view of one aspect of the embodiment of FIG. 1.

[0010]FIG. 4 is an end view of the embodiment illustrated in FIG. 1.

[0011]FIG. 5 is a side view of the embodiment of FIG. 1.

[0012]FIG. 6 is a top view of a series of vials incorporating aspects ofthe present invention.

[0013]FIG. 7 is an end view of the series of FIG. 6.

[0014]FIG. 8A is an end view of another embodiment of the presentdisclosure.

[0015]FIG. 8B is a side view of the embodiment of FIG. 8A.

[0016]FIG. 9A is an end view of another embodiment of the presentdisclosure.

[0017]FIG. 9B is a side view of the embodiment of FIG. 9A.

[0018]FIG. 10A is an end view of another embodiment of the presentdisclosure.

[0019]FIG. 10B is a side view of the embodiment of FIG. 10A.

DETAILED DESCRIPTION

[0020] The present disclosure provides a unique system for containingand delivering pre-measured products, such as liquids, drugs,medication, cosmetics, or other forms of unit of use products. It isunderstood, however, that the following disclosure provides manydifferent embodiments, or examples, for implementing different featuresof the invention. Specific examples of materials and arrangements aredescribed below to simplify the present disclosure. These are, ofcourse, merely examples and are not intended to limit the invention fromthat described in the claims. Well-known elements are presented withoutdetailed description in order not to obscure the present disclosure inunnecessary detail. For the most part, details unnecessary to obtain acomplete understanding of the present disclosure have been omittedinasmuch as such details are within the skills of persons of ordinaryskill in the relevant art.

[0021] Turning now to FIG. 1, there is illustrated a vial 10 accordingto one aspect of the present embodiments. The vial 10 can be made out ofany suitable material, such as a basic thermoplastic material, such aspolycarbonate, polyethylene, polyester, polystyrene, polypropylene,polysulfone, polyurethane, ethylene-vinyl-acetate and the like. Thematerial may be transparent or translucent and may be of differentcolors.

[0022] The vial 10 has two ends, a dispensing end 12 and a filling end14. At the filling end 14 there is an opening or hollow fill port 16.The structure of the fill port 16 includes an exterior elliptical end 18and an interior circular end 20. The exterior elliptical end 18 isdistal to the main body 22, while the interior circular end 20 isproximal to the main body 22. The circular end 20 is joined to the mainbody 22 of the vial 10. The main body 22 forms a cavity 23 for holdingthe product. The elliptical end 18 of the fill port 16 provides anexternal opening for use in filling the main body 22 with a product. Asillustrated, the circular end 20 flares out in a generally lateraldirection to create the elliptical end 18.

[0023]FIG. 2 is a end view of the vial 10. As illustrated in thisembodiment, the fill port is structured to include an elliptical end 18that tapers down to the circular cross-sectional shape of the circularend 20. The elliptical end 18 and the circular end 20 provide the fillport 16 with a structure that reduces the residual stresses within thevial 10 when the elliptical end 18 is sealed. Because the residualstresses are reduced, the seal is stronger and is less likely to fail.In addition, the structure of the fill port 16 is easily collapsible,which enables a reduced sealing cycle time as compared to sealing cycletimes of conventional vials.

[0024] Turning back to FIG. 1, it can be seen that the main body 22tapers down to a hollow neck 24. The hollow neck 24 may be used by theend user when dispensing product from the main body 22. The neck portion24 couples to a break-away tip 26.

[0025]FIG. 3 is a detail view of one embodiment of the break-away tip26. In this embodiment, the neck 24 is coupled to a round bulb 28. Theround bulb 28 contains a cavity 30 that is in hydraulic communicationwith the cavity 23 of the main body 22 via the hollow neck 24. The roundbulb 28 is surrounded by a relatively flat portion 32. The flat portion32 may have a reinforced edge 34 around its perimeter.

[0026]FIG. 4 is an end view of the break-away tip 26, showing the flatportion 32 and the round bulb 28.

[0027] Turning back to FIG. 3, the end user may use the flat portion 32to twist the tip 26 which will shear at the weakest cross section or“shear edge”. In this embodiment, the weakest cross-section is a shearedge 36, which is adjacent to the bulb 28. The shear edge 36 may beserrated to further reduce the cross-sectional area so that the cap 26will shear along the shear edge 36. In other embodiments, two roundbulbs could be used which would create a shear edge between them. Theuse of the round bulbs or shear edge reduces the distortion that couldoccur when the break-away tip 26 is twisted off. Distortion isundesirable because distortion could clog or reduce the product passagein the neck 24.

[0028] Turning now to FIG. 5, there is a side view of the vial 10. Theside view shows the fill port 16. From this view, it is evident that inthe transverse plane the fill port 16 may taper down from the circularend 20 to the elliptical end 18. FIG. 5 also shows the main body 22tapering down to the neck 24. The neck 24 is coupled to the bulb 34 ofthe break-away tip 26.

[0029] The vial 10 may be produced either by blow-molding procedures orby injection molding procedures. Additionally, the vial 10 may beproduced as a series of vials 40 as shown in FIG. 6. Each vial 40 a-40 emay be joined along common edges 42 a through 42 d, respectively. FIG. 7shows an end view of the series of vials 40 a through 40 e.

[0030] Although the structure of the fill port 16 is illustrated in FIG.1 to include an elliptical end 18 that tapers down to the circularcross-sectional shape of a circular end 20, other embodiments of thepresent disclosure provide alternative geometrical shapes orcombinations of shapes that are easily collapsible and that reduce oreliminate residual stresses within a vial being sealed. Referring now toFIGS. 8A-10B, other embodiments of the present disclosure areillustrated.

[0031] In FIG. 8A, an alternative structure for a hollow fill portaccording to the present disclosure is illustrated. The structure of thehollow fill port includes an exterior elliptical end 78 and an interiorelliptical end 80. As illustrated in FIG. 8B, the interior ellipticalend 80 is proximal to and joined to the main body 82 of a vial. Theexterior elliptical end 78 is distal to the main body 82. The main body82 forms a cavity for holding the product, while the exterior ellipticalend 78 provides an external opening that is used to fill the main body82 with a product. As illustrated in FIGS. 8A and 8B, the interiorelliptical end 80 is substantially the same size as the exteriorelliptical end 78. That is, the exterior elliptical end 78 does nottaper down to the interior elliptical end 80. The interior ellipticalend 80 and the exterior elliptical end 78 provide the fill port with astructure that is easily collapsible, which enables a reduced sealingcycle time as compared to sealing cycle times of conventional vials. Thestructure of the hollow fill port as illustrated by FIGS. 8A-8B alsoreduces the residual stresses that occur in the vial during sealing,which in turn results in a stronger seal that is less likely to fail.

[0032] In FIG. 9A, another structure for a hollow fill port according tothe present disclosure is illustrated. The structure of the hollow fillport includes an exterior diamond-shaped end 88 and an interior circularend 90. As illustrated in FIG. 9B, the interior circular end 90 isproximal to and joined to the main body 92 of a vial. The exteriordiamond-shaped end 88 is distal to the main body 92. The main body 92forms a cavity for holding the product, while the exteriordiamond-shaped end 88 provides an external opening that is used to fillthe main body 92 with a product. As illustrated in FIGS. 9A and 9B, theexterior diamond-shaped end 88 tapers down to the circularcross-sectional shape of the circular end 90. The circular end 90generally flares out, and the flared portions are shaped, to create thediamond-shaped end 88. The exterior diamond-shaped end 88 and thecircular end 90 provide the fill port with a structure that reduces theresidual stresses within the vial when the exterior diamond-shaped end88 is sealed. Because the residual stresses are reduced, the seal isstronger and is less likely to fail. In addition, the interior circularend 90 and the exterior diamond-shaped end 88 provide the fill port witha structure that is easily collapsible, which enables a reduced sealingcycle time as compared to sealing cycle times of conventional vials.

[0033] In FIG. 10A, yet another structure for a fill port according tothe present disclosure is illustrated. The structure of the fill portincludes an exterior diamond-shaped end 98 and an interiordiamond-shaped end 100. As illustrated in FIG. 10B, the interiordiamond-shaped end 100 is proximal to and joined to the main body 102 ofa vial. The exterior diamond-shaped end 98 is distal to the main body102. The main body 102 forms a cavity for holding the product, while theexterior diamond-shaped end 98 provides an external opening that is usedto fill the main body 102 with a product. As illustrated in FIGS. 10Aand 10B, the interior diamond-shaped end 100 is substantially the samesize as the exterior diamond-shaped end 98. That is, the exteriordiamond-shaped end 98 does not taper down to the interior diamond-shapedend 100. The interior diamond-shaped end 100 and the exteriordiamond-shaped end 98 provide the fill port with a structure that iseasily collapsible, which enables a reduced sealing cycle time ascompared to sealing cycle times of conventional vials. The structure ofthe hollow fill port as illustrated in FIGS. 10A-10B also reduces theresidual stresses that occur in the vial during sealing, which in turnresults in a stronger seal that is less likely to fail.

[0034] Any combination of the elliptical, circular and diamond-shapedgeometries of the embodiments illustrated by FIGS. 1-10B herein aresuitable to provide a structure that is easily collapsible and thatreduces the residual stresses that occur in the vial during sealing. Forexample, a diamond-shaped proximal end can be combined with anelliptical distal end. Other geometries not illustrated herein are alsosuitable. Using the teachings and suggestions of the present disclosure,those of ordinary skill in the art could design such alternativegeometries or combinations of geometries that are easily collapsible andthat reduce or eliminate residual stresses within a vial being sealed.Such alternatives are within the scope of the present disclosure.

Operation

[0035] Further operations of the present disclosure will now beexplained with reference to the embodiment illustrated in FIG. 1. Theembodiments illustrated in FIGS. 8A-10B are also suitable for use insuch further operations, as are other embodiments not illustratedherein, but within the means of those of ordinary skill in the art todesign, using the teachings and suggestions of the present disclosure.

[0036] Once the vials have been supplied to the packager, such as acompound pharmacy, the vials may be filled with a product by filling thefill port 16 until the cavity 23 contains the desired amount of product.The fill port 16 may then be sealed in a conventional manner, such as athermal impulse heat sealer or ultra-sonic sealer.

[0037] If the vial is to be used in conjunction with a nebulizer, an enduser, such as a patient or care-giver would twist the break-away tip 26and squeeze the product into the nebulizer bowl. The patient wouldinhale the fine mist created by the nebulizer.

[0038] Although only a few exemplary embodiments of this invention havebeen described in detail above, those skilled in the art will readilyappreciate that many modifications are possible in the exemplaryembodiments. Accordingly, all such modifications are intended to beincluded in the scope of this invention as defined in the followingclaims.

1. A container comprising a body defining a cavity, the body comprisinga dispensing end 12; and a filling end 14 having a hollow fill port 16,the hollow fill port comprising a circular end 20 proximal to the body;and an elliptical end 18 distal to the body.
 2. The container of claim 1wherein the dispensing end further comprises a hollow neck 24 inhydraulic communication with the cavity at a proximal end of the hollowneck with respect to the body; and a tip at a distal end of the hollowneck with respect to the body, the tip comprising a bulb 28 defining acavity in hydraulic communication with the hollow neck.
 3. The containerof claim 2 further comprising a relatively flat area 32 surrounding thebulb.
 4. The container of claim 2 further comprising an edge 34 defininga perimeter of the relatively flat area.
 5. The container of claim 2wherein the bulb and the neck define a shear edge.
 6. The container ofclaim 5 wherein the shear edge is serrated.
 7. The container of claim 2wherein the tip comprises two bulbs located adjacent to each other, eachbulb defining a cavity in hydraulic communication with the hollow neck;and a shear edge defined by an area between the two bulbs.
 8. Thecontainer of claim 1 wherein the elliptical end 18 defines an openingsuitable for use in filling the body with a product.
 9. The container ofclaim 1 wherein the circular end 20 flares out in a generally lateraldirection to create the elliptical end
 18. 10. The container of claim 1wherein the elliptical end tapers down to the circular end.
 11. Acontainer comprising a body defining a cavity, the body comprising adispensing end; and a filling end having a hollow fill port, the hollowfill port comprising a proximal end with respect to the body and adistal end with respect to the body, wherein the proximal end isselected from the group consisting of an elliptical end, a circular endand a diamond-shaped end, and wherein the distal end is selected fromthe group consisting of a diamond-shaped end and an elliptical end. 12.The container of claim 11 wherein the dispensing end further comprises ahollow neck in hydraulic communication with the cavity at a proximal endof the hollow neck with respect to the body; and a tip at a distal endof the hollow neck with respect to the body, the tip comprising a bulbdefining a cavity in hydraulic communication with the hollow neck. 13.The container of claim 12 further comprising a relatively flat area 32surrounding the bulb.
 14. The container of claim 12 further comprisingan edge defining a perimeter of the relatively flat area.
 15. Thecontainer of claim 12 wherein the bulb and the neck define a shear edge.16. The container of claim 15 wherein the shear edge is serrated. 17.The container of claim 12 wherein the tip comprises two bulbs locatedadjacent to each other, each bulb defining a cavity in hydrauliccommunication with the hollow neck; and a shear edge defined by an areabetween the two bulbs.
 18. The container of claim 11 wherein the distalend defines an opening suitable for use in filling the body with aproduct.
 19. The container of claim 11 wherein the distal end tapersdown to the proximal end.